This shop really shines … and sorts, simplifies, standardizes and sustains; the 5S principles are providing to be a powerful prelude and prerequisite to lean manufacturing at this aerospace job shop

Modern Machine Shop, Jan, 2004 by Mark Albert

5S is a catalyst for cellular manufacturing, too. The lathe area at Merritt Tool provides an example. "Once we had applied 5S, had standard operations in place and setup time reduced, we could visualize the flow of work more clearly," Mr. Simmons explains. By moving machines into one area, the shop accelerated that flow, cutting leadtimes significantly. Other cellular arrangements are now being studied, based on the positive results from this first cell.

Does Fun Start With S?

Given the intense pressure on manufacturing in the United States, 5S and other lean manufacturing techniques are more urgent than ever. This reality is certainly not lost on Merritt Tool. Nonetheless, Mr. Simmons acknowledges that shops should not overlook the potential for 5S to create some fun in the workplace.

"5S is serious business, but it offers numerous opportunities for people from different parts of the company to get together, work as a team and share pride in accomplishing improvements that benefit the whole company," he says. Working in a clean, well-organized and efficient workplace, which is what 5S is all about, adds to the quality of life as well.

That 5S leads to lean is clear enough at Merritt Tool. That 5S has a lighter side is all the more to recommend it.

To contact Merritt Tool Co., call (903) 983-1592 or visit www.merritttool.com.

Fig. 1--5S is not a cure-all, but its effects are far-reaching.

5S Benefits

* Improved safety

* Higher quality

* Lower costs

* More reliable deliveries

* Reduced setup and changeover lime

* Better use of floor space

* Fewer maintenance issues

* Greater operator job satisfaction

Fig. 2--TechSolve, a consulting group that helped introduce Merritt Tool to 5S, includes this list with the 5S advice it gives its clients.

Keys To 5S Success

* Get everyone involved.

* Integrate 5S into dally work.

* Communicate the need for 5S, the role of participants and how 5S is implemented.

* Be consistent in following 5S in all areas.

* Keep senior management involved. Their commitment is absolutely required.

* Follow through. Finish what is started.

* Link 5S to kaizen (Continuous improvement) activities.

I Need To 5S My Own Space

Visiting Merritt Tool was an eye-opening experience for me. Of course, 5S is all about seeing things differently. 5S relics heavily on visual clues to keep a workplace ready for high performance work. Just by looking around, a person can tell what's out of place or likely to cause a holdup that prevents a job from getting done on time. How to do things the right way ought to be equally obvious under 5S.

What I saw at Merritt Tool made me think about my own personal work spaces. My desk at work, for example, is rarely as neat as it should be. I started thinking about the minutes I spend from time to time searching for a missing folder or misplaced notes from a meeting I've attended. Where's that darn hole punch? Who took my scissors?

To keep this from happening, I need to apply 5S to this desk. The racks and stacks of project folders ought be categorized, labeled and prioritized. It's not just the time I would save or the frustration I would avoid by having material and tools at hand. I would have a better picture of what to do next based on importance and urgency. The inevitable interruptions from phone calls and visitors wouldn't get me off track as they tend to do now. I could stay focused more easily. 5S could help me think more clearly.